Waste Battery Recycling with Carbon-Nickel Ratio Particle Control
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Solution Overview
Problem
Existing methods for recycling waste batteries face challenges in controlling the size of the Ni-based alloy, leading to inefficient separation of valuable metals and increased process costs due to the use of water atomization, which generates significant carbon dioxide emissions and prolongs the leaching process time.
Innovation Solution
A method involving a controlled weight ratio of carbon to nickel in waste battery raw materials, with a heating process at specific temperatures and oxygen levels to form a Ni-based alloy with controlled particle sizes, facilitating easier separation and reducing carbon dioxide emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If water atomization is used to reduce alloy particle size, then the alloy particle size is reduced below a certain size, but the process costs increase significantly
Solution Approach 1:
The patent changes the carbon-to-nickel weight ratio parameter in the raw materials from the conventional range to 20 wt% or more (preferably 50-200 wt%). This parameter change modifies the reduction reaction characteristics, enabling the alloy to solidify into particles of appropriate size (75-1000 μm, preferably 200-500 μm) directly during the high-temperature reduction process, eliminating the need for water atomization and significantly reducing process costs
Solution Approach 2:
The patent performs preliminary action by controlling the carbon content in the raw materials before the reduction process. By pre-adjusting the carbon-to-nickel weight ratio to 20 wt% or more, the system prepares the conditions necessary for direct formation of appropriately sized alloy particles during reduction, avoiding the need for subsequent size reduction processes like water atomization
2Manufacturing precision
If the carbon content in raw materials is increased to control alloy size, then the alloy particle size is reduced, but the carbon dioxide emissions increase during the reduction process
Solution Approach 1:
The patent optimizes the carbon-to-nickel weight ratio to a specific range (20-200 wt%, preferably 50-150 wt%) rather than simply increasing carbon content indiscriminately. This optimized parameter range achieves the dual benefit of forming alloy particles of appropriate size (75-1000 μm) while controlling carbon consumption efficiency, thereby reducing CO2 emissions compared to excessive carbon addition
Solution Approach 2:
The patent implements feedback control by monitoring and adjusting the carbon-to-nickel weight ratio based on the desired alloy particle size and CO2 emission constraints. The optimized ratio range is determined through feedback from experimental data, balancing the competing requirements of particle size control and emission reduction
3Productivity
If the existing dry process is used with high temperature reduction, then valuable metals are recovered, but the alloy particle size is not controlled and water atomization is required
Solution Approach 1:
The patent introduces a new parameter control - the carbon-to-nickel weight ratio of 20 wt% or more - into the existing dry process. This parameter change fundamentally alters the solidification behavior of the alloy during reduction, enabling direct formation of particles in the desired size range (75-1000 μm) and eliminating the need for water atomization, thus maintaining high productivity while achieving precise particle size control
Solution Approach 2:
The patent creates a composite system by combining specific ratios of carbon-containing materials (such as battery anode materials like graphite or lithium carbon composite materials) with nickel-containing cathode materials. This composite raw material system ensures that during high-temperature reduction, the controlled carbon content facilitates the formation of alloy particles with appropriate size and morphology, eliminating post-processing requirements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively controls the alloy size for efficient separation of valuable metals, reducing process time and costs while minimizing carbon dioxide emissions.
Implementation Method 1
Ni-Mn-Li-Al-O oxides in the black powder are reduced at a high temperature using graphite and oxygen injection at a high temperature, for example, in a range of 1,400 to 1,600° C. so as to generate CO or CO2 gas
Implementation Method 2
oxygen injection at a high temperature, for example, in a range of 1,400 to 1,600° C. so as to generate CO or CO2 gas
Implementation Method 3
heating the introduced and charged waste battery raw materials... in a range of 1,050 to 1,300° C.
Data Source
AI summary
The present disclosure provides a method of recycling a waste battery, the method including: introducing and charging waste battery raw materials; heating the introduced and charged waste battery raw materials; cooling the heat-treated products; and discharging the cooled reactants, wherein in the introducing and charging of the waste battery raw materials, a weight ratio of carbon/nickel in the charged raw materials is 20 wt % or more.